How to Cut Polycarbonate Sheet

Looking to cut polycarbonate sheet but not sure how? This blog post will show you how to do it safely and effectively.

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Polycarbonate is a durable material that is used in a variety of applications, including bullet-resistant windows, aircraft windshields and greenhouses. It is a strong material that is difficult to cut without the proper tools and techniques. In this article, we will show you how to cut polycarbonate sheet using a few different methods.

Tools You Will Need

Polycarbonate is a durable material that is used in a variety of applications, including bulletproof windows, eyeglass lenses and software discs. If you need to cut polycarbonate sheet for any purpose, you can do so with standard woodworking tools. However, there are a few things you need to keep in mind to get the best results.

First, polycarbonate is a tough material, so it will require sharp blades. You can use either a hand saw or power saw, but make sure the blades are fresh and sharp. Second, because polycarbonate is transparent, it can be difficult to see where you are cutting. It helps to use a pencil or grease pencil to mark your cut lines before you begin cutting.

To cut polycarbonate sheet, you will need:
-A hand saw or power saw with sharp blades
-A straightedge or guide
-A pencil or grease pencil

Making the Cut

Polycarbonate is a durable, tough material that is frequently used in today’s engineering and construction projects. It is transparent to visible light, has high impact strength, and can withstand extreme temperatures. Polycarbonate sheet can be cut using a variety of methods, including sawing, scoring and breaking, grinding, and milling.

When sawing polycarbonate sheet, it is important to use a fine-toothed blade with as few teeth per inch as possible. You will also want to use coolant or lubricant when sawing to help extend the life of your blade and prevent melting. Synthetic lubricants such as “Stickco” or “Kool Mist” are ideal.

To score and break polycarbonate sheet, you will need a sharp utility knife and a straightedge. Score the sheet deeply along your line of cut, then bend the sheet back and forth until it snaps cleanly along the score line.

Grinding can be used to create smooth cuts in thicker sheets of polycarbonate. To do this, you will need a grinding wheel designed for plastics (not metal) mounted in a bench grinder. Once again, you will want to use coolant or lubricant when grinding to help extend the life of your wheel and prevent melting. As with sawing, synthetic lubricants such as “Stickco” or “Kool Mist” are ideal.

Milling is the best method for creating complex shapes or very precise cuts in polycarbonate sheet. To do this, you will need access to a CNC router or milling machine.

Finishing Up

Now that you have your cuts all laid out, it’s time to start cutting Depending on what tools you’re using, the process will vary slightly.

If you’re using a saw, make sure the blade is sharp and designed for cutting plastic. A dull blade will cause the polycarbonate to melt, rather than cut cleanly. If you’re using a power saw, set the blade speed to around 1,000 FPM (feet per minute). For a hand-held saw, plunge the blade into the sheet following your pencil line as best you can. Slowly and carefully guide the saw along the cut line until you reach the end.

If you’re using a router, use a plastic-cutting bit with a 45 degree angle and a spiral flute design. Set the speed of the router around 18,000 RPM. For best results, use a guidefence or edge guide with your router so that it cuts along a straight line. Slowly feed the router along your cut line until you reach the end.

Once you’ve made all your cuts, remove any burrs or sharp edges with sandpaper or a file. You can also use a heat gun to smooth out any rough edges – just be careful not to overheat the plastic, as this can cause it to warp.